Systems and methods for coupling conductors to conductive contacts of electrical stimulation systems

• US 8,214,054 B2
• Filed: 04/07/2009
• Issued: 07/03/2012
• Est. Priority Date: 04/07/2009
• Status: Expired due to Fees

• Current Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Original Assignee: Boston Scientific Neuromodulation Corporation (Boston Scientific Corporation)
• Inventors: Barker, John Michael
• Primary Examiner(s): Layno, Carl H
• Assistant Examiner(s): WU, EUGENE T
• Application Number:
  US12/419,763
• Publication Number:
  US 20100256694A1
• Time in Patent Office: 1,183 Days
• Field of Search: 607/46, 607115-117, 607/119, 607/122, 600372-374, 600/377, 600/378
• US Class Current: 607/115
• CPC Class Codes: A61N 1/05 for implantation or insertion into the body, e.g. heart electrode A61N1/06 takes precedence
• CPC Class Codes: A61N 1/0551 Spinal or peripheral nerve electrodes
• CPC Class Codes: A61N 1/3752 Details of casing-lead connections
• CPC Class Codes: H01R 13/5224 for medical use
• CPC Class Codes: H01R 13/621 Bolt, set screw or screw clamp
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 2201/12 for medicine and surgery
• CPC Class Codes: H01R 24/58 Contacts spaced along longitudinal axis of engagement
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/4921 with bonding

Abstract

An electrical stimulation lead includes a plurality of conductive contacts disposed at a distal end and a proximal end of a lead body. The plurality of conductive contacts includes a plurality of electrodes and a plurality of terminals. At least one of the conductive contacts is a first conductive contact that includes at least one adhesive aperture defined between an inner surface and an outer surface of the at least one conductive contact. A plurality of conductors each electrically couple at least one of the electrodes to at least one of the terminals. Each first conductive contact has a conductor associated with, and electrically coupled to that first conductive contact. The adhesive is disposed in proximity to the at least one adhesive aperture of at least one first conductive contact to adhesively couple that first conductive contact to the at least one associated conductor.

Claims

1. An electrical stimulation lead comprising:

a lead body with a proximal end, a distal end, and a longitudinal length;

a plurality of conductive contacts disposed at the distal end and the proximal end of the lead body, the plurality of conductive contacts comprising

a plurality of electrodes disposed on the distal end of the lead, and

a plurality of terminals disposed on the proximal end of the lead,

wherein at least one of the conductive contacts is a first conductive contact that comprises a plurality of adhesive apertures and at least one contact aperture, the plurality of adhesive apertures and the at least one contact aperture each defined between an inner surface and an outer surface of the first conductive contact, wherein the plurality of adhesive apertures are longitudinally aligned along one side of the first conductive contact;

a plurality of conductors, each conductor electrically coupling at least one of the electrodes to at least one of the terminals, wherein each first conductive contact has at least one of the conductors associated with, and electrically coupled to that first conductive contact;

a weld disposed on the inner surface of the at least one first conductive contact in proximity to the at least one contact aperture of the at least one first conductive contact to electrically couple that first conductive contact to the at least one associated conductor; and

a non-conductive adhesive disposed in proximity to the plurality of adhesive apertures of at least one first conductive contact to mechanically couple that first conductive contact to the at least one associated conductor.

2. The lead of claim 1, wherein the plurality of adhesive apertures comprises a recess in the outer surface of the at least one first conductive contact, the recess defining a first opening to the inner surface of the at least one first conductive contact.

3. The lead of claim 2, wherein the at least one associated conductor extends through the first opening from inside the lead body to the outer surface of the at least one first conductive contact.

4. The lead of claim 3, wherein the recess defines a second opening to the inner surface of the at least one first conductive contact, and wherein the at least one associated conductor extends through the second opening from the outer surface to the inner surface of the at least one first conductive contact.

5. The lead of claim 1, wherein the lead body defines at least one lumen through which the at least one associated conductor extends.

6. The lead of claim 5, wherein the adhesive is disposed in proximity to the plurality of adhesive apertures such that the adhesive is disposed in the lumen.

7. The lead of claim 6, wherein the adhesive is disposed in the lumen such that the adhesive is contained beneath the at least one first conductive contact by seals in the lumen at either end of the at least one first conductive contact.

8. The lead of claim 1, further comprising a conductor-carrying element extending along the longitudinal length of the lead body, the conductor-carrying element defining a plurality of conductor lumens.

9. The lead of claim 8, wherein the at least one associated conductor extends along at least a portion of at least one of the plurality of conductor lumens.

10. The lead of claim 1, wherein the lead body is isodiametric.

11. The lead of claim 1, wherein the first conductive contact is one of cylindrical shaped or C-shaped.

12. The lead of claim 1, wherein the plurality of adhesive apertures are longitudinally aligned with the at least one contact aperture along one side of the first conductive contact.

13. The lead of claim 1, wherein for each of the plurality of adhesive apertures an entire perimeter of the adhesive aperture is formed by the first conductive contact.

14. The lead of claim 1, wherein the non-conductive adhesive is disposed on the inner surface of the at least one conductive contact.

15. An electrical stimulating system comprising:

an electrical stimulating lead comprising a lead body with a proximal end, a distal end, and a longitudinal length;

a plurality of conductive contacts disposed at the distal end and the proximal end of the lead body, the plurality of conductive contacts comprising

a plurality of electrodes disposed on the distal end of the lead, and

a plurality of terminals disposed on the proximal end of the lead,

wherein at least one of the conductive contacts is a first conductive contact that comprises a plurality of adhesive apertures and at least one contact aperture, the plurality of adhesive apertures and the at least one contact aperture each defined between an inner surface and an outer surface of the first conductive contact, wherein the plurality of adhesive apertures are longitudinally aligned along one side of the first conductive contact;

a plurality of conductors, each conductor electrically coupling at least one of the electrodes to at least one of the terminals, wherein each first conductive contact has at least one of the conductors associated with, and electrically coupled to that first conductive contact;

a weld disposed on the inner surface of the at least one first conductive contact in proximity to the at least one contact aperture of the at least one first conductive contact to electrically couple that first conductive contact to the at least one associated conductor; and

a non-conductive adhesive disposed in proximity to the plurality of adhesive apertures of at least one first conductive contact to mechanically couple that first conductive contact to the at least one associated conductor;

a control module configured and arranged to electrically couple to the proximal end of the lead, the control module comprising

a housing, and

an electronic subassembly disposed in the housing; and

a connector for receiving the lead, the connector having a proximal end, a distal end, and a longitudinal length, the connector configured and arranged to receive the lead, the connector comprising

a connector housing defining a port at the distal end of the connector, the port configured and arranged for receiving the proximal end of the lead, and

a plurality of connector contacts disposed in the connector housing, the connector contacts configured and arranged to couple to at least one of the plurality of terminals disposed on the proximal end of the lead.

16. The electrical stimulating system of claim 15, further comprising a lead extension having a proximal end and a distal end, the connector disposed on the distal end of the lead extension.

17. The electrical stimulating system of claim 16, wherein the lead extension comprises:

a lead extension body with a proximal end, a distal end, and a longitudinal length;

a plurality of terminals disposed at the proximal end of the lead extension body, wherein at least one of the terminals is a first terminal that comprises at least one adhesive aperture and at least one contact aperture, the at least one adhesive aperture and the at least one contact aperture each defined between an inner surface and an outer surface of the first terminal;

a plurality of conductors, each conductor electrically coupled to art least one of the terminals, wherein each first terminal has at least one of the conductors associated, and electrically coupled, to that first terminal;

a weld disposed on an inner surface of the at least one first terminal in proximity to the at least one contact aperture of the at least one first terminal to electrically couple that first terminal to the at least one associated conductor; and

a non-conductive adhesive disposed in proximity to the at least one adhesive aperture of the at least one first terminal to mechanically couple the at least one first terminal to the at least one associated conductor.